Overhaul Procedures: Disassembly

CAUTION:

Automatic transaxles consist of delicate parts. Be careful not to damage them in disassembly and assembly.
Spread a rubber mat on a workbench and keep it clean.
Do not use cotton or muslin fiber. Use nylon fabric or paper towel.
Cleanse the disassembled components. Clean metal parts with a general cleaning agent or dry them with a blower.
Clean clutch discs, thrust plates made of resin, and rubber parts with automatic transaxle fluid and keep them dust free.
If transaxle body has been damaged, disassemble and clean cooler system.

Remove the torque converter (A).

Fig 1: Locating Torque Converter
Courtesy of KIA MOTORS AMERICA, INC.
Remove each bracket.
Remove the wiring harness bracket.
Remove the oil pan (A) (Bolt:19 EA).

Fig 2: Identifying Oil Pan Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil filter (A) (Bolt:3 EA).

Fig 3: Identifying Oil Filter And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the valve body(Bolt:21 EA).
NOTE: 6x30□(A): 17EA, 6x35□(B): 1EA, 6x40□(C): 1EA, 6X55mm(D):1EA, 6x60□(E): 1EA

Fig 4: Identifying Valve Body Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the two O-rings from low & reverse brake and transfer drive gear hole.

Fig 5: Locating O-Rings Of Low & Reverse Brake
Courtesy of KIA MOTORS AMERICA, INC.

Remove each accumulator piston, a new seal ring and the springs.

NOTE: Accumulator spring identification

ACCUMULATOR SPRING IDENTIFICATION CHART

NO.	Use	I.D. Color	Spring number
A	U/D clutch	White/White	2
B	O/D clutch	Yellow	1
C	2ND brake	White	2
D	L/R brake	Yellow	1

Fig 6: Locating Accumulator Piston, Seal Ring And Springs

Courtesy of KIA MOTORS AMERICA, INC.

Remove the control valve connector (A) and mounting clip (B).

Fig 7: Locating Control Valve Connector And Mounting Clip
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil level gauge (A) and bracket(Bolt:2EA).

Fig 8: Locating Oil Level Gauge, Bracket And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift cable bracket (A) (Bolt:2EA).

Fig 9: Locating Shift Cable Bracket And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the plug(A) (Bolt:1EA).

Fig 10: Locating Plug And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the output shaft speed senor (A) (Bolt:1EA).

Fig 11: Locating Output Shaft Speed Senor And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the input shaft speed senor (A) (Bolt:1EA).

Fig 12: Locating Input Shaft Speed Senor And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the torque converter housing (Bolt:17EA).

Fig 13: Locating Torque Converter Housing And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil separate (A) (Bolt:3EA).

Fig 14: Locating Oil Separate And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil seal(A) from the torque converter housing.

Fig 15: Locating Oil Seal Of Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the differential gear assembly(A).

Fig 16: Locating Differential Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool(09453-2F100), remove the differential outer race(A).

Fig 17: Locating Differential Outer Race Using Special Tool (09453-2F100)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the two O-rings.

Fig 18: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump(A) (Bolt:7EA).
CAUTION: Do not disassemble the oil pump. Misalignment during assembly may damage the pump and the transaxle.

Fig 19: Locating Oil Pump And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump gasket(A).

Fig 20: Locating Oil Pump Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust washer(A).

Fig 21: Locating Thrust Washer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the underdrive clutch(A).

Fig 22: Locating Underdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing(A).

Fig 23: Locating Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the underdrive clutch hub(A).

Fig 24: Locating Underdrive Clutch Hub
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil guide plate(A).

Fig 25: Locating Oil Guide Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the parking rod guide (A) and the oil plate (B) (Bolt:2EA).

Fig 26: Locating Parking Rod Guide, Oil Plate And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the inhibitor switch (A) and the manual control lever (B).
(Inhibitor switch - Bolt:2EA, control lever shaft - Nut:1EA).

Fig 27: Locating Inhibitor Switch And Manual Control Lever
Courtesy of KIA MOTORS AMERICA, INC.
Remove the parking sprag (A), shaft (B) and sprag spring (C).

Fig 28: Locating Parking Sprag, Shaft And Sprag Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the driven gear and the outer race.
Remove the plate (A) (1 reamer bolt).

Fig 29: Locating Plate (Reamer Bolt)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the detent spring(A).

Fig 30: Locating Detent Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the manual shaft mounting groove bolt.

Fig 31: Locating Manual Shaft Mounting Groove Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reamer bolt from the detent lever.
Remove the manual control shaft(A) (including the two O-rings), the detent lever(B) and the parking rod(C).

Fig 32: Locating Manual Control Shaft, Detent Lever And Parking Rod
Courtesy of KIA MOTORS AMERICA, INC.
Remove the feed tube (A) (4 gaskets, 2 eye bolts).

Fig 33: Locating Feed Tube (Gaskets, Eye Bolts)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rear cover (A) (Bolt:9EA).

Fig 34: Locating Rear Cover And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the five O-rings from the transaxle.

Fig 35: Identifying O-Rings Of Transaxle
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust race (A) from the rear cover.

Fig 36: Locating Thrust Race Of Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the four seal rings from the rear cover.

Fig 37: Locating Seal Rings Of Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (45851-23000).

Fig 38: Locating Thrust Bearing (45851-23000)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse & overdrive clutch(A).

Fig 39: Locating Reverse & Overdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (45798-39060).

Fig 40: Locating Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the overdrive hub(A).

Fig 41: Locating Overdrive Hub
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing(45798-39060).

Fig 42: Locating Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse sun gear(A).

Fig 43: Locating Reverse Sun Gear
Courtesy of KIA MOTORS AMERICA, INC.
Remove the piston mounting snap ring(A).

Fig 44: Locating Piston Mounting Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 2ND brake piston(A).

Fig 45: Locating 2nd Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 2ND brake return spring(A).

Fig 46: Locating 2nd Brake Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 2ND brake pressure plate(A), the brake discs(B), the brake plates(C), the brake reaction plate(D) and the snap ring(E).

Fig 47: Identifying 2nd Brake Pressure Plate, Brake Discs, Brake Plates, Brake Reaction Plate And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.

Fig 48: Locating 2nd Brake Pressure Plate, Brake Discs, Brake Plates, Brake Reaction Plate And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Low & reverse planetary gear set (A).

Fig 49: Removing Low & Reverse Planetary Gear Set
Courtesy of KIA MOTORS AMERICA, INC.
Remove the inner race mounting snap ring(A).

Fig 50: Locating Inner Race Mounting Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the one way clutch inner race(A).

Fig 51: Locating One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.
Remove the snap ring(A).

Fig 52: Locating Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the low & reverse brake discs(A), plates(B) and pressure plate(C).

Fig 53: Identifying Low & Reverse Brake Discs, Plates And Pressure Plate
Courtesy of KIA MOTORS AMERICA, INC.

Fig 54: Locating Low & Reverse Brake Discs, Plates And Pressure Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the wave spring(A).

Fig 55: Locating Wave Spring
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09493-2F400), remove the snap ring(A).

Fig 56: Removing Snap Ring Using Special Tool (09493-2F400)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the low & reverse brake spring retainer(A).

Fig 57: Locating Low & Reverse Brake Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the return spring(A).

Fig 58: Locating Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the low & reverse brake piston(A).

Fig 59: Locating Low & Reverse Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transfer drive gear (A) (Screw:8 EA).

Fig 60: Locating Transfer Drive Gear And Screw
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09453-2F100), remove the outer race and spacer of differential bearing from converter housing.
Using the special tool (09453-2F100), remove the outer race of differential bearing from converter housing.